Roll compaction systems are essential in industrial, nutraceutical, and pharmaceutical manufacturing, comprising three key components: (1) feed system, (2) roll compactor, and (3) mill. This process, also known as dry granulation, involves the compression of fine powders between two rotating rolls to eliminate air and form a compact. The properties of the compact, such as particle size and density, can be tailored by adjusting system settings. Various roll profiles are available resulting in flat, wavy, or stick like compact depending on the feed material characteristics and desired final product.
Choosing the appropriate roll profile is crucial for achieving the desired results in roll compaction. The roll profile creates friction between the powder and the roll surface, facilitating the compaction process. Adjustment of parameters such as the speed of feed screws, roll gap, and roll speed allows for optimization of this frictional force. By controlling these variables, manufacturers can ensure uniform compaction and consistent product quality.
Lab testing has consistently demonstrated the efficacy of the fixed blade IPA Mill as the preferred size reduction unit for reducing compacts to the desired particle size. This mill utilizes fixed blades to break down the compacted material into granules of uniform size, ensuring homogeneity and facilitating downstream processing. The efficiency of the IPA Mill in achieving precise particle size reduction contributes to the overall effectiveness of the roll compaction system.
In summary, the roll compaction process relies on the interplay of the feed system, compactor, and mill to produce high-quality granules for all industry applications. By selecting the appropriate roll profile and utilizing the IPA Mill for size reduction, manufacturers can optimize the efficiency and performance of roll compaction systems, resulting in consistent and reliable production.
